From Bean to bar processing
Cleaning & classification
Cleaning & classification equipment handle the first step in cocoa processing. The removal of impurities and defective beans is essential at this stage. Eliminate impurities, spoiled beans and bugs from your beans to ensure your product is safe for consumption. Sift through your fine flavour cocoa on our table for manual classification, or sort large volumes of beans with our mechanical and 3-stage classifier.
JAF Inox cleaning & classification equipment helps you to select only the best beans for roasting.
By cleaning and sorting your cocoa prior to roasting you ensure no traces of foreign material remain among your beans. Germinated beans should be removed to avoid flavour contamination prior to roasting. Additional mold and remaining germs will be killed at the roasting stage, whilst shells and residue will be removed through winnowing.
Consumer safety is a priority in any food production, which is why JAF Inox designed their equipment with health and safety in mind. All parts in contact with your product are executed in AISI 304 stainless steel or food-graded plastic and easy to clean.
Start your flavour story with a perfect roast
Whether you prefer the depth of a dark roasted – Cuban Baracoa or a fine roasted Forastero – Roasting is all about finding the right balance between heat and time to release the full potential of your beans. To create, refine, innovate and develop the ultimate chocolate experience.
Fruity, earthy, or floral; bring out the unique flavour profile of your fine flavour beans with a perfect roast. Enhance those fruity notes of a Madagascan Sambirano or the intensity of Javan dark – vary from bean to nib roasting, light to dark roasts: from flavour to flavour, batch to batch.
JAF Inox roasters provide you with full control of the roasting process; allow you to specify temperature and time, to excel your craftsmanship and bring out those desirable qualities. Temperatures can be set for consistency or modified for flexibility.
The efficient heat exchange of our roasters guarantee a homogeneous treatment with low energy consumption; that sterilizes your beans, extracts unwanted volatiles and moisture while gently loosen shells from their nibs.
Winnowing eliminate shells, flat, broken or unevenly fermented beans from your cocoa nibs. (Roasted) cocoa beans are fed into the adjustable feed and are broken by a hammer mill with adaptable angle, intensity and speed. After breaking, the shells are separated from the cracked nibs: variable amplitude of the 5 vibratory sieves thrash the cracked beans, whilst intensity controlled suction columns draw off the shell residue into the cyclone.
Our continuous-sieve-winnower with cyclone is easy to operate and maintain and ensures less than 1.75% of shell in the nibs. Separates in 5 sizes, and is easy to clean. Variable conditions can be fully modified from batch to batch or set to repeat by the operator.
When nib roasting is required, winnowing occurs prior to roasting.
Grinding – cocoa liquor
Roasted nibs are ground until friction and heat reduces them to a thick paste known as cocoa mass or cocoa liquor. Cocoa liquor contains both ground cocoa and cocoa butter. When cocoa butter is removed from the cocoa mass (using a butter press) its known as pressed-cake. Cocoa mass, liquor and kibbled cakes are used by chocolatiers and chocolate manufactures for further processing into chocolate.
JAF Inox offers milling equipment and butter presses are available at Royal Duyvis Wiener
In order to reduce particle size, nibs are crushed by the batch knife mill through quick and efficient milling to obtain a homogeneous mass while maintaining aroma and flavour. The batch knife mill has low energy consumption and all parts in contact with the product are manufactured from stainless steel. After milling the cocoa liqour is ready for fine grinding.
After cocoa is mixed with additional ingredients such as sugar, and Lecithins (oil or butter) your mixture is ready for refining in the roll refiner. Further reduction of particle size is essential for the fine, smooth texture of quality chocolate. JAF Inox Roll Refiner ensures an adequate rheological (soft solid flow) consistency of your chocolate.
The completely cooled surface of the rollers with their adjustable speed and distance always reduce particles to the required size. The high precision rollers ensure a homogeneous particle distribution of your cocoa mass, compound, chocolate and creams.
The rolls are covered with hardened, polished steel. The speed and distance of the rolls can be mechanically adjusted.
JAF Inox offers diffrent types of conching: single shaft conche for small capacities, double shaft conches and longitudinal conches. De-moisturization, flavour development and the extraction of undesirable volatiles along with precise control of temperature are some of the main characteristics of our conches. They fine-grind your cocoa into a perfectly homogeneuos mass. No additives are required to produce the finest chocolate.
The single and double shaft conche can be used for all types of chocolate. The single shaft conch is particularly suitable for chocolate with a high cocoa content. It has a special design for clockwise mixing and counter clockwise conching with shear stress. The jacketed double shaft conches achieve high efficiency and use high shear. Both types have specially designed blades for perfect shear distribution and effective mixing. Speed and rotation are frequency controlled. Water and chocolate temperature is monitored by a PT-100 sensor. The longitudinal conche is often used when taste has higher priority than capacity. The traditional technology, improved with modern temperature controls, and exhaustion, provides excellent flavour development and the extraction of undesired volatile acids.
Tempering is the process of applying heat and movement to chocolate in order to stabilize the crystallization of fatty acids and sugar, to solidify fat and crystals evenly and prevent fat & sugar bloom. Tempered chocolate has a higher melting point and preserves for a longer time. Well tempered chocolate gives chocolate the all important snap and glossy shine that every chocolate maker seeks.
By heating the chocolate (between 37-48 Degrees C) the fat acids will melt. Tempering starts above 32C. By keeping the chocolate mass in motion the distribution of crystals will form evenly. Bits of tempered chocolate are then added to stimulate the crystallization process. This method is called seeding or tempering by addition.
We offer different types of tempering equipment for obtaining the required pre-crystallisation of cocoa or chococlate. Either batch-wise or continuous, our tempering machines ensure the correct viscosity for your product. They facilitate de-moulding and provide chocolate with excellent characteristics. The compact tempering machine promotes the formation of crystals by adding solid chocolate and is suitable for lab scale plants. We also offer a 3-stage tempering process, either batch-wise or continuous, for large capacities.
Depositing, moulding, enrobing
JAF Inox equipment offers you flexibility in manufacturing moulded, enrobed and filled products. Easy to operate and guaranteeing a perfectly shaped product. Our equipment is suitable for various recipes.
Our Flex tempering machine is our most flexible and versatile solution which combines tempering, dropping and enrobing within a compact machine. The dropping depositor with 16 pistons, has a minimum depositing cycle of 3 seconds and the depositing range can vary from 3 to 50 grams per piston. Different volumes, number of rows and columns can be selected. During production, the tempering machine is automatically filled by the buffer tank, while it in turn automatically fills the depositor. This continuous product flow avoids interruptions and fluctuations in the production process.
The temperature of the chocolate is controlled by the continuous pre-crystallizer , which ensures a constant product temperature and therefore a homogeneous product. After moulding the product is fed into the cooling tunnel.
For enrobing the product is deposited on the cooled belt and a perfect coverture is brought onto top and bottom. The production process has visual access so can easily be monitored by the operator. After enrobing, the products are fed into the cooling tunnel. Temperature and humidity in the cooling tunnel are digitally controlled. This tunnel is executed in stainless steel with a polyurethane belt.
The cooling process is the last step in the chocolate processing when moulds pass through the cooling tunnel. The tunnel is build to create an optimum environment for the solidification of your chocolate. At JAF Inox we supply cooling tunnels in different sizes; all with hygienic polyurethane belts.
JAF Inox equipment offers your flexibility in the manufacturing process moulded, enrobed and filled products are fed into the cooling tunnel for solidification. This tunnel is executed in stainless steel with a polyurethane belt. Temperature and humidity in the cooling tunnel are digitally controlled.